Rear Differentials: Removal & Installation Subaru BRZ ZC

Replacement

Note. The following procedure is for LH side. Perform the same procedures for the RH and LH side.

Scheme 113

Scheme 114

1. Removal of front tire
2. Removal of front disc brake caliper ASSY LH Remove 2 bolts, and disconnect the disc brake caliper ASSY LH from the steering knuckle. CAUTION: Suspend the caliper using a wire, etc.
3. Removal of front disc (Refer to «DISASSEMBLY»(ref-619202-S40418523682014053000000) )
4. Removal of front axle hub & bearing ASSY LH Using the SST and a hydraulic press, push out the hub bolt from the front axle hub & bearing ASSY. CAUTION: Do not hammer the hub bolts. This may deform the front axle hub & bearing ASSY. Do not reuse the hub bolt. SST 28399AG000 NOTE: Because the front axle hub & bearing ASSY can not be disassembled, only hub bolts can be removed.
5. Installation of front axle hub & bearing ASSY LH Install the front axle hub & bearing ASSY to the SST securely. Using a press, press the new hub bolts until their seating surfaces come in contact snugly with the front axle hub & bearing ASSY. SST 927080000 NOTE: Use the 12 mm (0.47 in) dia. holes in the SST to prevent bolts from tilting.
6. Installation of front disc (Refer to «INSTALLATION»(ref-619202-S26548450392014053000000) )
7. Installation of front disc brake caliper ASSY LH Install the disc brake caliper ASSY LH to the steering knuckle with 2 bolts. Standard value: T=80N.m {816kgf.cm} {59.0ft.lbf}
8. Installation of front tire Standard value: T=120N.m {1224kgf.cm} {88.5ft.lbf}

Scheme 115

Removal

Note. The following procedure is for LH side. Perform the same procedures for the RH and LH side.

Scheme 116

Scheme 117

1. Removal of front tire
2. Removal of front disc brake caliper ASSY LH (Refer to «REPLACEMENT»(ref-619162-S29571419202014053000000) )
3. Removal of front disc (Refer to «DISASSEMBLY»(ref-619202-S40418523682014053000000) )
4. Disconnection of speed sensor FR LH Remove the bolt, and disconnect the speed sensor FR LH from the steering knuckle. CAUTION: Keep the tip and mounting portion of the speed sensor FR LH free from foreign matter. The speed sensor FR LH is easily damaged. When removing the speed sensor FR LH from the front axle hub & bearing ASSY LH, do not apply excessive force or turn the sensor.
5. Removal of front axle hub & bearing ASSY LH Remove 4 bolts, and remove the front axle hub & bearing ASSY from the steering knuckle.

Installation

Note. The following procedure is for LH side. Perform the same procedures for the RH and LH side.

1. Installation of front axle hub & bearing ASSY LH Install the front axle hub & bearing ASSY to the steering knuckle with 4 bolts. Standard value: T=65N.m {663kgf.cm} {47.9ft.lbf}
2. Inspection of front axle hub & bearing ASSY axial play (Refer to «INSTALLATION»(ref-619162-S14876919332014053000000) )
3. Inspection of front axle hub & bearing ASSY runout (Refer to «INSTALLATION»(ref-619162-S14876919332014053000000) )
4. Installation of speed sensor FR LH Install the speed sensor FR LH to the steering knuckle with a bolt. Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf} CAUTION: Do not damage the tip of the speed sensor when installing the speed sensor body. Do not allow foreign matter to attach to the mounting surfaces. Be careful not to twist the speed sensor wire during installation.
5. Installation of front disc (Refer to «INSTALLATION»(ref-619202-S26548450392014053000000) )
6. Installation of front disc brake caliper ASSY LH (Refer to «REPLACEMENT»(ref-619162-S29571419202014053000000) )
7. Installation of front tire Standard value: T=120N.m {1224kgf.cm} {88.5ft.lbf}
8. Inspection of test mode (speed sensor check) (Refer to «WORK SUPPORT»(ref-619151-S00270732952014053000000) )

On-Vehicle Inspection

Note. The following procedure is for LH side. Perform the same procedures for the RH and LH side.

Scheme 118

Scheme 119

1. Removal of front tire
2. Removal of front disc brake caliper ASSY LH (Refer to «REPLACEMENT»(ref-619162-S29571419202014053000000) )
3. Removal of front disc (Refer to «DISASSEMBLY»(ref-619202-S40418523682014053000000) )
4. Inspection of front axle hub & bearing ASSY axial play Inspect axial play of the bearing near the axle hub inner periphery (flange portion) using a dial gauge. Limit: 0.05mm {0.00196in} CAUTION: If it exceeds the limit, replace the front axle hub with a new part.
5. Inspection of front axle hub & bearing ASSY runout Inspect runout of the axle hub near the axle hub outer periphery using a dial gauge. Limit: 0.05mm {0.00196in} CAUTION: If it exceeds the limit, replace the front axle hub with a new part.
6. Installation of front disc (Refer to «INSTALLATION»(ref-619202-S26548450392014053000000) )
7. Installation of front disc brake caliper ASSY LH (Refer to «REPLACEMENT»(ref-619162-S29571419202014053000000) )
8. Installation of front tire Standard value: T=120N.m {1224kgf.cm} {88.5ft.lbf}

Scheme 120

Note. The following procedure is for LH side. Perform the same procedures for the RH and LH side.

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

1. Removal of front axle hub LH (Refer to «REMOVAL»(ref-619162-S06825355592014053000000) )
2. Removal of disc brake dust cover FR LH Remove 3 bolts, and remove the disc brake dust cover FR LH.
3. Disconnection of tie-rod end SUB-ASSY LH Remove the cotter pin, and then remove the castle nut. Use a tie-rod ball joint puller to detach the tie-rod end SUB-ASSY LH from the steering knuckle. WARNING: Apply lubricant to the thread and the tip of the tie-rod ball joint puller bolt. CAUTION: Always tie a string to the steering knuckle without slack to prevent the tie-rod ball joint puller from falling. Install the tie-rod ball joint puller so as to make A parallel to B with the nut located in the center. Otherwise the dust cover may be damaged. Always use a wrench at the point shown in the figure. Do not damage the ball joint boot of the tie-rod end SUB-ASSY LH. Do not damage the steering knuckle. Do not damage the disc brake dust cover FR.
4. Disconnection of front suspension lower arm ASSY LH Remove the cotter pin and nut. Install the tie-rod ball joint puller to the thread of the front suspension lower arm ASSY LH. Use a tie-rod ball joint puller to detach the front suspension lower arm ASSY LH. WARNING: Apply lubricant to the thread and the tip of the tie-rod ball joint puller bolt. CAUTION: Install the tie-rod ball joint puller so as to make the body parallel to the claw with the nut located in the center. Otherwise the dust cover of the front suspension lower arm ASSY may be damaged. Always tie a string to the vehicle without slack to prevent the tie-rod ball joint puller from falling. Do not damage the dust cover of the front suspension lower arm ASSY. Do not damage the front suspension lower arm ASSY. Do not damage the disc brake dust cover FR. Do not damage the steering knuckle.
5. Removal of steering knuckle LH Remove the 2 bolts and 2 nuts to remove the steering knuckle LH. CAUTION: Secure the bolt and turn the nut.

Note. The following procedure is for LH side. Perform the same procedures for the RH and LH side.

1. Installation of steering knuckle LH Install the steering knuckle LH with 2 bolts and 2 new nuts. Standard value: T=155N.m {1581kgf.cm} {114.3ft.lbf}
2. Installation of front suspension lower arm ASSY LH Install the front suspension lower arm ASSY LH with the nut. Standard value: T=51N.m {520kgf.cm} {37.6ft.lbf} Install a new cotter pin.
3. Installation of tie-rod end SUB-ASSY LH Install the tie-rod end SUB-ASSY LH to the steering knuckle LH with the nut. Standard value: T=27N.m {275kgf.cm} {19.9ft.lbf} Install a new cotter pin. CAUTION: When aligning the clip holes after tightening the castle nut, tighten the castle nut further but within 60°.
4. Installation of disc brake dust cover FR LH Install the front disc brake dust cover to the steering knuckle with 3 bolts. Standard value: T=18N.m {184kgf.cm} {13.3ft.lbf}
5. Installation of front axle hub & bearing ASSY LH (Refer to «INSTALLATION»(ref-619162-S14876919332014053000000) )
6. Inspection and adjustment of front wheel alignment (Refer to «FRONT WHEEL ALIGNMENT»(ref-619173-S12285229782014053000000) )
7. Mid point setting of the VSC (VDC) sensor (Refer to «WORK SUPPORT»(ref-619151-S00270732952014053000000) )

Scheme 127

Note. The following procedure is for LH side. Perform the same procedures for the RH and LH side.

Scheme 128

Scheme 129

1. Removal of rear tire
2. Disconnection of rear disc brake caliper ASSY LH (Refer to «INSPECTION»(ref-619167-S41009138902014053000000) )
3. Removal of rear disc (Refer to «DISASSEMBLY»(ref-619197-S05223412392014053000000) )
4. Removal of rear axle hub bolt & bearing ASSY LH Using the SST and a hydraulic press, push out the hub bolt from the rear axle hub & bearing ASSY. CAUTION: Do not hammer the hub bolts. This may deform the rear axle hub & bearing ASSY. Do not reuse the hub bolt. SST 28399AG000 NOTE: Because the rear axle hub & bearing ASSY can not be disassembled, only hub bolts can be removed.
5. Installation of rear axle hub bolt LH Install the rear axle hub & bearing ASSY to the SST securely. Using a press, press the new hub bolts until their seating surfaces come in contact snugly with the rear axle hub & bearing ASSY. SST 927080000 NOTE: Use the 12 mm (0.47 in) dia. holes in the SST to prevent bolts from tilting.
6. Installation of rear disc (Refer to «REAR BRAKE FLEXIBLE HOSE»(ref-619197-S29171848892014053000000) )
7. Connection of rear disc brake caliper ASSY LH (Refer to «PARKING BRAKE SWITCH ASSY»(ref-619167-S02124716852014053000000) )
8. Installation of rear tire Standard value: T=120N.m {1224kgf.cm} {88.5ft.lbf}

Scheme 130

Note. The following procedure is for LH side. Perform the same procedures for the RH and LH side.

Scheme 131

Scheme 132

Scheme 133

1. Removal of rear tire
2. Disconnection of speed sensor RR LH Remove the bolt, and then remove the speed sensor. CAUTION: Keep the tip and mounting portion of the speed sensor RR free from foreign matter.
3. Removal of rear axle shaft nut LH Remove the crimp of the rear axle shaft nut LH. CAUTION: Completely release the crimp of the nut to avoid damage to the thread of the rear drive shaft ASSY LH. Remove the rear axle shaft nut using a socket wrench. CAUTION: Do not loosen the rear axle shaft nut LH with the rear axle loaded. Doing so may damage the rear axle hub and bearing ASSY LH.
4. Removal of rear drive shaft ASSY (Refer to «REMOVAL»(ref-619198-S21937440882014053000000) )
5. Disconnection of rear disc brake caliper ASSY LH (Refer to «INSPECTION»(ref-619167-S41009138902014053000000) )
6. Removal of rear disc (Refer to «DISASSEMBLY»(ref-619197-S05223412392014053000000) )
7. Removal of rear axle hub and bearing ASSY LH Remove 4 bolts, and remove the rear axle hub and bearing ASSY LH from the rear axle carrier. NOTE: Suspend the rear backing plate and the parking brake shoe with a string, etc.

Note. The following procedure is for LH side. Perform the same procedures for the RH and LH side.

Scheme 134

1. Installation of rear axle hub and bearing ASSY LH Install the rear axle hub and bearing ASSY LH to the rear axle carrier with 4 bolts. Standard value: T=65N.m {663kgf.cm} {47.9ft.lbf}
2. Installation of rear disc (Refer to «REAR BRAKE FLEXIBLE HOSE»(ref-619197-S29171848892014053000000) )
3. Installation of rear drive shaft ASSY (Refer to «INSTALLATION»(ref-619198-S08320759702014053000000) )
4. Connection of rear disc brake caliper ASSY LH (Refer to «PARKING BRAKE SWITCH ASSY»(ref-619167-S02124716852014053000000) )
5. Installation of rear axle shaft nut LH CAUTION: Always clean the drive shaft even if it is new. Clean and remove oil, foreign matter, etc. completely. Install a new rear axle shaft nut LH using a socket wrench. Standard value: T=190N.m {1938kgf.cm} {140.1ft.lbf} CAUTION: Do not crimp the rear axle shaft nut LH. NOTE: After the inspection of the rear axle hub and bearing ASSY LH play and runout, crimp the rear axle shaft nut LH.
6. Inspection of rear axle hub & bearing ASSY axial play (Refer to «ON-VEHICLE INSPECTION»(ref-619162-S08629609272014053000000) )
7. Inspection of rear axle hub & bearing ASSY runout (Refer to «ON-VEHICLE INSPECTION»(ref-619162-S08629609272014053000000) )
8. Securing of rear axle shaft nut LH Crimp the rear axle shaft nut LH using a chisel and a hammer.
9. Installation of speed sensor RR LH Install the speed sensor RR LH with a bolt. Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf} CAUTION: Keep the tip and mounting portion of the speed sensor RR LH free from foreign matter.
10. Installation of rear tire Standard value: T=120N.m {1224kgf.cm} {88.5ft.lbf}
11. Adjustment of parking brake lever free play (Refer to «SYMPTOM TABLE»(ref-619167-S22668140342014053000000) )
12. Inspection of test mode (speed sensor check) (Refer to «WORK SUPPORT»(ref-619151-S00270732952014053000000) )

Note. The following procedure is for LH side. Perform the same procedures for the RH and LH side.

Scheme 135

Scheme 136

1. Removal of rear tire
2. Disconnection of rear disc brake caliper ASSY LH (Refer to «INSPECTION»(ref-619167-S41009138902014053000000) )
3. Removal of rear disc (Refer to «DISASSEMBLY»(ref-619197-S05223412392014053000000) )
4. Inspection of rear axle hub & bearing ASSY axial play Inspect axial play of the bearing near the axle hub inner periphery (flange portion) using a dial gauge. Limit: 0.05mm {0.00196in} CAUTION: If it exceeds the limit, replace the rear axle hub & bearing ASSY with a new part.
5. Inspection of rear axle hub & bearing ASSY runout Inspect runout of the bearing near the axle hub outer periphery using a dial gauge. Limit: 0.05mm {0.00196in} CAUTION: If it exceeds the limit, replace the rear axle hub & bearing ASSY with a new part.
6. Installation of rear disc (Refer to «REAR BRAKE FLEXIBLE HOSE»(ref-619197-S29171848892014053000000) )
7. Connection of rear disc brake caliper ASSY LH (Refer to «PARKING BRAKE SWITCH ASSY»(ref-619167-S02124716852014053000000) )
8. Installation of rear tire Standard value: T=120N.m {1224kgf.cm} {88.5ft.lbf}

Scheme 137

Note. The following procedure is for LH side. Perform the same procedures for the RH and LH side.

Scheme 138

Scheme 139

Scheme 140

Scheme 141

Scheme 142

Scheme 143

1. Removal of rear axle hub & bearing ASSY LH (Refer to «REMOVAL»(ref-619162-S09082989032014053000000) )
2. Disassembly of parking brake (Refer to «INSPECTION»(ref-619167-S41009138902014053000000) )
3. Disconnection of rear stabilizer link SUB-ASSY (installed on LH side) (Refer to «REMOVAL»(ref-619196-S10063326182014053000000) )
4. Disconnection of parking brake cable ASSY NO. 3 Remove the clip, and detach the parking brake cable ASSY NO. 3 from the back plate.
5. Disconnection of upper control arm ASSY RR LH Remove the bolts and nuts, and detach the upper control arm ASSY RR LH from the rear axle carrier.
6. Disconnection of rear suspension arm ASSY NO. 1 LH Remove the bolts and nuts, and detach the rear suspension arm ASSY NO. 1 LH from the rear axle carrier.
7. Disconnection of rear suspension arm ASSY NO. 2 LH Remove the bolts and nuts, and detach the rear suspension arm ASSY NO. 2 LH from the rear axle carrier.
8. Disconnection of toe control link SUB-ASSY LH Remove the cotter pin. Remove the nut. Using a tie-rod ball joint puller, detach the toe control link SUB-ASSY LH from the rear axle carrier. WARNING: Apply lubricant to the thread and the tip of the tie-rod ball joint puller bolt. CAUTION: Install the tie-rod ball joint puller so as to make the body parallel to the claw with the nut located in the center. Otherwise the dust cover of the toe control link SUB-ASSY may be damaged. Always tie a string to the vehicle without slack to prevent the tie-rod ball joint puller from falling. Do not damage the dust cover portion of the toe control link SUB-ASSY. Do not damage the toe control link SUB-ASSY. Do not damage the parking brake plate SUB-ASSY. Do not damage the rear axle carrier.
9. Removal of parking brake plate SUB-ASSY LH
10. Removal of rear axle carrier LH Remove the rear axle carrier LH while supporting the drive shaft. CAUTION: Do not damage the drive shaft outboard joint boot. Do not push out the rear axle ASSY more than necessary to the vehicle outside. NOTE: Suspend the drive shaft ASSY using a rope or wire, etc.

Note. The following procedure is for LH side. Perform the same procedures for the RH and LH side.

1. Installation of rear axle carrier LH Using a jack, lift the rear axle carrier and align the installation position of each arm. CAUTION: Use a jack with wooden blocks so that the rear axle carrier will not be damaged.
2. Temporary tightening of upper control arm ASSY RR LH Install the upper control arm ASSY RR LH to the rear axle carrier, and temporarily tighten it with new bolts and nuts.
3. Temporary tightening of rear suspension arm ASSY NO. 1 LH Install the rear suspension arm ASSY NO. 1 LH to the rear axle carrier, and temporarily tighten it with new bolts and nuts.
4. Temporary tightening of rear suspension arm ASSY NO. 2 LH Install the rear suspension arm ASSY NO. 2 LH to the rear axle carrier, and temporarily tighten it with new bolts and nuts.
5. Installation of toe control link SUB-ASSY LH Install the toe control link to the rear axle carrier with the nut. Standard value: T=60N.m {612kgf.cm} {44.2ft.lbf} Install the cotter pin.
6. Temporary tightening of rear stabilizer link SUB-ASSY (installation position LH side) (Refer to «DISPOSAL»(ref-619196-S36340355612014053000000) )
7. Installation of parking brake cable ASSY NO. 3 Install the parking brake cable ASSY NO. 3 to the rear axle carrier with the clip.
8. Assembly of parking brake (Refer to «PARKING BRAKE SWITCH ASSY»(ref-619167-S02124716852014053000000) )
9. Stabilization of vehicle (Refer to «DISPOSAL»(ref-619196-S36340355612014053000000) )
10. Final tightening of upper control arm ASSY RR LH Tighten the mounting bolts and nuts of the upper control arm ASSY RR LH. Standard value: T=80N.m {816kgf.cm} {59.0ft.lbf}
11. Final tightening of rear suspension arm ASSY NO. 1 LH Tighten the mounting bolts and nuts of the rear suspension arm ASSY NO. 1 LH. CAUTION: Secure the nut and turn the bolt. Standard value: T=110N.m {1122kgf.cm} {81.1ft.lbf}
12. Final tightening of rear suspension arm ASSY NO. 2 LH Tighten the mounting bolts and nuts of the rear suspension arm ASSY NO. 2 LH. Standard value: T=80N.m {59kgf.cm} {59.0ft.lbf}
13. Tightening of rear stabilizer link SUB-ASSY (installation position LH side) (Refer to «DISPOSAL»(ref-619196-S36340355612014053000000) )
14. Installation of rear axle hub & bearing ASSY LH (Refer to «INSTALLATION»(ref-619162-S41924572302014053000000) )
15. Inspection and adjustment of rear wheel alignment (Refer to «REAR WHEEL ALIGNMENT»(ref-619173-S10065507292014053000000) )
16. Inspection and adjustment of headlight «ADJUSTMENT»(ref-619164-S02642911452014060900000)
17. Mid point setting of the VSC (VDC) sensor (Refer to «WORK SUPPORT»(ref-619151-S00270732952014053000000) )